Re-Usage Of Waste Foundry Sand In Medium Strength Concrete
SONARGAON UNIVERSITY
DEPARTMENT OF CIVIL ENGINEERING
Submitted By
Name ID
MD AL-IMRAN BCE-1602008011
MAHMUDUR RAHMAN ZIHAD BCE-1602008230 MD. TANVIR HOSSAIN BCE-1602008191 ASHRAFUZZAMAN ARIF BCE-1503006006 ABDUR GAFFAR BCE-1602008176
Supervised by
MD. LUTFOR RAHMAN
Assistant Professor
,Department of Civil Engineering Sonargaon University (SU) 147/I, Green Road, Dhaka-1215
FALL-2019
LETTER OF TRANSIMITTAL
To
Md. Lutfor Rahman Assistant Professor, Head, Supervisor, Project & Thesis
Head of Civil Engineering Department Sonargaon University
Subject: Submission of Thesis Report
Dear Sir, With profound reference towards the dignity of yours, we are submitting thesis paper on " Re-usage of waste foundry sand in high-strength concrete "
Thank you Sir for assigning us with this report.
We are grateful and thankful to you for the kind hand of help, support and guidance that you extended to me while preparing this report and always during the course.
I hope and pray that you would be kind enough to redirect us if there is any mistake anywhere in way Sincerely yours,
Section: 8A+8E
Name ID
MD AL-IMRAN BCE-1602008011
MAHMUDUR RAHMAN ZIHAD BCE-1602008230
MD. TANVIR HOSSAIN BCE-1602008191
ASHRAFUZZAMAN ARIF BCE-1503006006
ABDUR GAFFAR BCE-1602008176
Re-Usage of Waste Foundry Sand In Medium-Strength Concrete
A THESIS BY
MD AL-IMRAN BCE-1602008011 MAHMUDUR RAHMAN ZIHAD BCE-1602008230 MD. TANVIR HOSSAIN BCE-1602008191 ASHRAFUZZAMAN ARIF BCE-1503006006 ABDUR GAFFAR BCE-1602008176
In partial fulfillment of the requirement for the degree of Bachelor of Science (B.Sc.) in Civil Engineering
FALL-2019
DEDICATED TO OUR PARENTS &TEACHERS
SONARGAON UNIVERSITY
DEPARTMENT OF CIVIL ENGINEERING
CERTIFICATE
The thesis titled "Re-usage of waste foundry sand in high-strength concrete”, Submitted by Md Al-Imran, Mahmudur Rahman Zihad, Md. Tanvir Hossain, Ashrafuzzaman Arif & Abdyr Gaffar, Session: Fall-2019 has been accepted as satisfactory in partial fulfillment of the requirement for the degree of Bachelor of Science (B.Sc.) in Civil Engineering.
………..
Md. Lutfor Rahman
Assistant Professor, Head, Supervisor, Project & Thesis
Head of Civil Engineering Department Sonargaon University
DECLARATION
We do hereby solemnly declare that the work presented in this report has been carried out by us under the supervision of Md. Lutfor Rahman( Assistant Professor,
Head of Civil Engineering Department); we have tried our best to make the report with accurate with information and relevant data.We hereby ensure that, the work that has been presented dose not breach any existing copyright. We further undertake to indemnify the university against any loss or damage arising from breach of the forgoing obligation.
MD AL-IMRAN BCE-1602008011
……….
MAHMUDUR RAHMAN ZIHAD BCE-1602008230
……….
MD. TANVIR HOSSAIN BCE-1602008191
……….
ASHRAFUZZAMAN ARIF BCE-1503006006
……….
ABDUR GAFFAR
BCE-1602008176
ACKNOWLEDGEMENT
At first we would like to express eternal gratitude to the Almighty for the successful completion of this study.
We would like to express our earnest gratitude to our supervisor,Md.
LutforRahman (Assistant Professor, Head of Civil Engineering Department) for giving us an opportunity to work on such an important topic. There continuous guidance, essential suggestions and invaluable judgment are greatly acknowledged.
Their keen interest in this topic and wholehearted support on our effort was a source of stimulation to carry out the study. We consider ourselves fortunate to work under his supervision.
We are extremely indebted to Assistant Professor Md. Lutfor Rahman, Head of Civil Engineering Department, Sonargaon University (SU) for providing necessary infrastructural and resources to accomplish our research work.
There was no way that would have been possible to successfully finished to this research work without help and support of dedicated technical stuffs of the Civil Engineering Department laboratory for their kind and sincere co-operation throughout the experimental work.
At the same time, we are greatly indebted to Professor Dr. Md. Abul Basher(Pro- Vice-Chancellor of Sonargaon University) for his continuoussupport to carry out our study and permitted us to use all types of facilities as well as laboratory.
The authors are grateful to their parents and family for their deep support and continuous encouragement and patience that helped them to be what they are today.
The Authors MD AL-IMRAN
MAHMUDUR RAHMAN ZIHAD MD. TANVIR HOSSAIN
ASHRAFUZZAMAN ARIF
ABDUR GAFFAR
ABSTRACT
In this study, the potential re-use of waste foundry sand in high-strength concrete production was investigated. Because Concrete is currently one of the most widely used construction material.
Mainly our research was for take a decision to use this concrete as a medium-strength concrete with decrease the materials costing by use a waste (valueless) materials which is Foundry Sand.
Foundry Sand produce from Re-Rolling mill. Billet heat by 1200-1500 degree Celsius Temperature to produce MS Bar, Angle etc. Then the fracture of the Billet (like as Rust) fall down and finally it’s the Foundry Sand.
So we used Foundry sand (which is a waste materials & has no value) as a alternative of Fine Aggregate. For use it we can decrease the concrete costing.
The natural fine-sand is replaced with waste foundry sand (50%, 60%, 70%and 100%). The findings result from a series of test program has shown increasing in compressive strength which is directly related to waste foundry inclusion in concrete. Nevertheless the concrete with 10%
waste foundry sand exhibits almost similar results to that of the control one. The workability of the fresh concrete decreases with the increase of the waste foundry sand ratio.
The obtained results satisfied the acceptable limits set by the American Concrete Institute (ACI), which is for normal concrete is 20 Mpa to 25 Mpa and we got the strength by use of Foundry Sand is 25.08 Mpa. We used the different percentage of Foundry Sand replaced by Fine Aggregate that’s 50%, 60%, 70%and 100%In concrete mix we used W/C ratio 0.48, concrete mix ratio was 1:1.5:3. Compressive strength calculation of all those samples and their comparison was the basic theme of the research. For this purpose cylinders were casted and checked under Universal Testing Machine (UTM) for compressive strength.
Table of Contents
Chapter I
1.1 General ...1
1.2 Background ...2
1.3 Objectives of the Study ...3
1.4 Methodology ...4
1.5 Research Flow Diagram ...6
1.6 Research Significance ...7
Chapter -II 2.1 General ………..………...……8
2.2 Refractory Sands………...……….………9
2.3 Types of Refractory ………....………...………...………..……..9
2.4 Refractory sand grains………..…………..….…...10
2.5 Uses of Foundry Sand ……….………...……..….10
2.5.1 Foundry Sand Grain Shape……….….……...11
2.6. Beneficial Application Of Foundry Sand ……….………...……..12
2.6.1 Structural Fill ……….………….…….…....12
2.6.2 Manufacturing another Product ……….…….………….………12
2.6.3 Soil Manufacturing and Amendment ……….……….…….13
2.6.4 Landfill Uses ………..………..13
2.6.5 Pipe Bedding and Backfill ………..……….13
2.6.6 Asphalt work……….13
2.6.7 Portland Cement……..………..……14
2.6.8 Rock Wool………14
2.6.9 Fine Aggregate for Concrete Block ……….14
2.6.10 Hydraulic Barrier In Landfill Final Cover ……….…………14
Chapter -III Molding Sand
3.1 Constituents of molding sand………..……….19
3.2 Molding material………..19
3.3 Silica sand………19
3.4 Moisture……….………..20
3.5 Additives………..………20
Chapter -IV Experiential Materials 4.1 Properties of molding sand……….……….21
4.1.1 Refractoriness ……….21
4.1.2 Permeability ……….21
4.1.3 Cohesiveness ………...……….22
4.1.4 Green strength………...……22
4.1.5 Dry strength………...………. 22
4.1.6 Flow ability or plasticity ……….…….…22
4.1.7 Adhesiveness ………..…..……23
4.1.8 Collapsibility ………...……….23
4.1.9 Miscellaneous properties ……….………23
4.2 Fine aggregate……….………26
4.2.1 Fineness Modulus ………...….27
4.3Cement……….……….27
4.4Coarse aggregate………..……….27
4.5Water………...………..28
4.6. Mix proportion...29
4.6.1 Mixing and Casting of Sample Concrete...30
4.6.3 Curing of Specimen ...31
4.7 Experiments and Testing...31
4.7.1Curing of Concrete Cylinder...32
Chapter -V Results & Discussion
5.1 Slump Cone test results…...………...33
5.2 Compaction factor test results…...………...35
5.3 Compressive strength test…...………...36
5.3.1 Compressive Strength for 14th day…...………...36
5.3.2 Compressive Strength for 21th day…...………...36
5.3.2.1 Compressive Strength for 21th day with curing…...………...…....…..37
5.3.3 Compressive Strength for 28 days...41
5.3.3.1 Compressive Strength for 14 days curing after Compressive Strength...41
5.3.3.2 Compressive Strength for 28th days with curing ...42
5.3.3 Compressive Strength for dry...43
5.3.4.1 Compressive Strength for 14th with dry...43
5.3.4.2 Compressive Strength for 28th day with dry...43
5.4 Fracture surface...45
5.5. Water Absorption……….…...…...…...47
Chapter -VI Conclusions and Recommendations 6.1: CONCLUSIONS………..………..49
6.2: FUTURE RECOMMENDATIONS………..……….50
6.3 REFERENCES………51
Appendix-I………..………...52
LIST OF FIGURE
Fig:1.0- Waste Foundry Sand………..…………..04
Figure 1.1(a):- Universal Testing Machine (UTM) & Sieve Analysis……….…….04
Figure:- 1.2 Slump Test……….………...………05
Figure:- 1.3 Cylinder Compact & Curing………...…………...…...05
Figure 1.2: Flow diagram of methodology………05
Figure 2.1:- Some Book About Foundry Sand in below……….……...………...…09
Figure 2.5 (1):- Flow able fill…...……….16
Figure 2.5 (2):- Road Embankment……….………..16
Figure 2.5 (3):-Hydraulic Barrier in Landfill Final Cover………..………...17
Figure 2.5 (4):- Structural Fill………..………..17
Figure 2.5 (5):-Application of Foundry Sand………...……….18
Figure 2.5 (6):-Asphalt work…...….……….18
Figure 2.5 (7):-Pipe Bedding and Backfill ……….………...……….18
Figure 4.4 (1):- Roughing Mill of Re-Rolling Mill from where we get the Foundry …….……..23
Figure 4.4 (2):- Inter Mill & Outer Mill of Re-Rolling Mill from where we get the Foundry Sa...……24
Figure 4.4 (3):- Molten metal gets poured into the sand-based molds during sand casting……..24
Figure. 4.4 (4): Waste Foundry Sand…...………..………20
Figure: 4.5 Sylhet Sand………..………...…26
Figure 4.6: The Cement which used in the Concrete……….28
Figure 4.7:- 25mm Downgrade Stone chips………...………...29
Figure 5.1:- The slump test………...….33
Figure 5.2:- fracture surface………...…………47
LIST OF TABLE
Table 4.1. Physical properties of waste foundry sand………...………25
Table 4.2. Properties of Fine Aggregate………..………..26
Table: 4.2.1 Fineness Modulus ……….27
Table 4.3. Properties of cement ………..………..27
Table 4.4. Properties of Coarse Aggregate………22
Table 4.5 pH Value Test………...23
Table 4.6. Mix Proportion (M20)……….……...………23
Table4. 7. Mix Proportions of Concrete…...……….24
Table5.1.Workabilityof all mixtures………..………26
Table 5.2. Compaction Factor Test (WFS)………27
Table5.3.1 Compressive Strength for 14th day…………...……..28
Table 5.3.2.1 Compressive Strength 21th day with curing………...……..29
Table 5.3.2.2Compressive Strength for 14 days curing after Compressive Strength test 21th days………31
Table 5.3.3.1 Compressive Strength for 14 days curing after Compressive Strength test 28th days………....32
Table 5.3.3.2 Compressive Strength 28th days with curing ……….33
Table 5.3.4.1 Compressive Strength 14th day with dry………..34
Table 5.3.4.2 Compressive Strength 28th day with dry……….35
LIST OF GRAPH
GRAPH 4.1 Mix Proportions of Concrete……….………32
GRAPH 5.1 Workability of all mixtures ………..34
GRAPH 5.2 Compaction Factor Test (WFS &NS)……….…..35
Graph 5.3.1 Conventional concrete SL No vs Failure load (KN)………..………37
Graph 5.3.2. Conventional concrete SL No vs Failure load (KN)……… 38
Graph 5.3.2 Conventional concrete vs Concrete Weight (gm)………..………38
Graph 5.3.2. Conventional concrete SL No vs Load (KN)………40
Graph 5.3.3.1 . Conventional concrete SL No vs Failure load(KN)……….……….42
Graph 5.3.3.2 Conventional concrete SL No vs Failure load(KN)………...……….43
Graph 5.3.4.1 Conventional concrete SL No vs Failure load(KN)………..………..44
Graph 5.3.4.2 Conventional concrete SL No vs Failure load(KN)………45
